General information

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This technical information is provided as general guidelines how to design hydraulic piping systems. In the design of a specic piping system the environment, the customers specications as well as local rules, regulations and laws must be followed at all times.

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Process Design........................................................................484 Mechanical Design.................................................................485 Attachments Pressure drop in pipes............................................................488 Pressure drop in bends, couplings, etc..................................489 Oil ow rates at recommended max. velocities...................490 Recommended connection technology 50 bar..................491 Recommended connection technology 210 bar................492 Recommended connection technology 280 bar................493 Recommended connection technology 350 bar................494 Recommended connection technology 420 bar................495 Hose size selection nomogram..............................................496 Pressure drop in hoses...........................................................497 Bending radius theory for hoses...........................................498 Spacing for clamps.................................................................499 Linear expansion of steel pipes.............................................500 Thread identication.............................................................501 Cleanliness..............................................................................502

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GS-HYDRO PRODUCT CATALOGUE

GENERAL INFORMATION

Process Design Introduction Process Design

Hydraulic systems are designed for such a working pressure that the required forces and torques are achieved. The machinery, equipment and components of a hydraulic system are typically designed so that a 15% increase in the working pressure is possible. The components of the system have to be selected in such a manner that the working parameters (pressure, ow rate etc.) are not exceeded taking into account the possible increase in the working pressure. All design paramaters have to be selected specically for each case taking into account the customers requirements as well as local rules, regulations and laws. The pipes are dimensioned in such a manner that the pressure loss in the system does not exceed the maximum allowable value (pressure) at the maximum (or design) ow rate. The pressure loss in a piping system is related to the square of the velocity of the uid ( p ~ v2). Therefore, the initial design is typically done based on the velocity of the uid. If required, the pressure loss in the systems is then checked in order to verify that the maximum acceptable pressure loss (and the maximum allowable working pressure of the piping) is not exceeded. The nomographic charts of pressure drops are shown in attachment 1.

Fluid (oil) Velocities

GS-Hydros recommendation in regards to the oil velocities to be utilised for intial pipe sizing are as follows: a) Suction lines
Viscosity [mm2/s = cSt] 150 100 50 30 Maximum velocity v [m/s] 0.6 0.75 1.2 1.3

The suction line is typically dimensioned so that the velocity does not exceed 1.3 m/s. b) Pressure lines
Pressure p [bar] 25 50 100 200 > 200 Maximum velocity oil ow < 10 l/min v [m/s] 12 12 12 23 23 Maximum velocity oil ow > 10 l/min v [m/s] 2.53 3.54 4.55 5(6) 5(6)

The pressure line is typically dimensioned so that the velocity does not exceed 5 m/s. c) Return lines The recommended return line velocity is 1...3 m/s. The return line is typically dimensioned so that the velocity does not exceed 3 m/s. The oil ow rates at the recommended velocities are presented in attachment 2.

484

Mechanical Design Introduction Mechanical Design

When designing the piping system the following has to be taken into account: pipe & tube material connection technology: fittings, flanges, welding hoses and hose couplings pipe supports

Pipe & Tube Materials

GS-Hydro recommends the use of cold-drawn, seamless precision (carbon) steel tubes & pipes (St37.4 NBK and St52.4 NBK) and austentic stainless steel (AISI316L) tubes and pipes due to quality (precision in dimension and shape) and cleanliness reasons (no scale). As a comparison hot rolled tubes will always have some scale both inside and out due to the manufacturing process; by cold forming there will not be any scale inside the tube after the manufacturing.

The recommended pipe & tube materials to be used in hydraulic applications are as follows:
Carbon Steel Material Specication Manufacturing Tolerances Technical Terms of Delivery Material Specication Manufacturing Tolerances DIN 1630 DIN 2391-1 DIN 2391-2/C Stainless Steel (mm) ASTM A269/A213 (A.W.) ASTM A269 EN 10305-4 Stainless Steel (sch) ASTM A312 ASTM A999 EN 10305-4

GS-Hydro recommends the use of cold drawn seamless high tensile hydraulic tube according to DIN 2391C ST52.4 NBK (E 355N) because the higher tensile strength means higher permissible working pressures and reduced wall thickness, leading to reduced overall weight in both the tube and pipe itself as well as in the necessary supporting steel structures.

485

GENERAL InfORMATION

MachInes

The use of DIN 2391C ST37.4 NBK (E 235N) which is also recommendable material grade - leads to thicker tube and pipe walls and thus more weight (and potentially costs). The nal selection between St.37.4 and St 52.4 is, however, an economical decision.

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GENERAL INFORMATION

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GENERAL INFORMATION

Mechanical Design Fittings and Flanges

In hydraulic and other piping systems with high quality requirements GS-Hydro recommends the use of non-welded connection technologies (ttings, anges etc.) for all tube and pipe sizes due to the reliability and inherent cleanliness. The type of jointing technology is selected based on the working pressure and the tube or pipe size. The material is selected based on the environment (and/ or the customers specications). For tube and pipe sizes above and including 25 mm GS-Hydro recommends the use of the GS-37 Flare Flange and/or GS-Retain Ring Systems. For tube and pipe sizes below 25 mm GS-Hydro recommends advanced tting solutions, 37 JIC are or high quality bite type (prole ring) ttings depending on the application and specic design requirements. The recommended connection technology for various pipe sizes and pressure classes are shown in attachment 3. Selection of type of connection In order to select the type of connection (ange, tting, etc) the following basic design data is needed: Working pressure, bar [W.P] Pipe/tube material Pipe/tube size (OD x s) Other conditions such as possible pressure shocks in the system, external forces, environment (thermal movements, corrosion etc.) and noise aot.

Attached tables provide a guideline what type of connection to select for various materials and tube/pipe sizes. The tables which are intended as a general guideline are used as follows: 1. Select the correct table in accordance with the tube/pipe material and maximum system working pressure: 50 bar, carbon steel/stainless steel 210 bar, carbon steel/stainless steel 280 bar, carbon steel/stainless steel 350 bar, carbon steel/stainless steel 420 bar, carbon steel/stainless steel 690 bar, Duplex steel

2. Select connection type based on tube/pipe size (or oil ow) Note! Other connection types than those recommended in the tables are also possible. Prior to making the nal selection tubes/ pipes, anges/ttings etc must to checked for compliance with local rules and regulations, system working pressure and other design conditions.

486

Mechanical Design

Hoses & Hose Couplings

Hydraulic hoses are used in wide variety of industrial hydraulic systems. Dimensions, performance specications, construction options, and features are all important parameters to consider when searching for hydraulic hose. Dimensions for the selection of hydraulic hose include inside diameter, outside diameter, and minimum bend radius The inside diameter refers to the inside of the hose or liner. The outside diameter is often a nominal specication for hoses of corrugated or pleated construction. Minimum bend radius is based on a combination of acceptable hose cross-section deformation and mechanical bending limit of any reinforcement. Important performance specications to consider when searching for hydraulic hose & hose couplings include application, material to be conveyed, working pressure and temperature range. The working pressure is the maximum service design pressure. The temperature range is the full required range of ambient operating temperature. See attachment 4.

When designing the piping system supports the following should be taken into account: The pipes shall not be supported from other pipes nor should the pipes be utilised to support other components The transfer of vibration from other equipment and machinery should be avoided to the extent possible Thermal expansions shall be taken into account when designing the supports A pipe bend should be supported as close to the bend as possible (whenever needed on both sides of the bend) The support should be located as close to the end of the pipe as possible when connecting to hose.

The pipe clamps should be made of both a mufing material and a which resists wear (when the pipe moves). Pipe clamps conforming to DIN 3015-1...3 should be utilised. The recommended (typical) maximum spacing between clamps in Marine and Industrial applications is shown in attachment 5. The nal spacing of the clamps has to be selected based on the specic requirements of the application in question. There can be large variations in tempearture in hydraulic systems, especially in marine and offshore applications. Under certain conditions the temperature can vary from for instance 40C during periods in the winter to +40C in the summer. This results in the thermal expansion of the pipes. For instance with a temperature difference of 80C the lenght will vary almost 1.0 mm per 1 meter of pipe. The linear expansion of steel pipes is presented in attachment 6.

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GENERAL INFORMATION

GS-HYDRO PRODUCT CATALOGUE

GENERAL INFORMATION

Attachments Attachment 1a. Pressure Drop in Pipes

Laminar p bar x m 1 V m/sek Q l/min. Turbulent 0.5 0.4 5 0.3 1000 500 1 0.2 Example A 0.5 5 10 Turbulent 100 50 20 p bar x m 10 50 30 100 10000 5000 50 Re

d1 mm
60

40

15

0.1 0.1 Example B Laminar 0.05 1 10 5 10 9 0.01 0.05 0.04 0.5 0.03 0.001 0.001 0.5 1 8 7 6

4 0.02

Q = 80 l/min., pipe 22/19 Pressure drop per meter pipeline is searched for. Example A is drawn from d = 19 mm throug Q = 80 l /min. It crosses the Re-line in the turbulent area and the result can be read on the turbulent scale. p= 0.23 bar x m

At another viscosity a correction is to be made as follows:

p p =

nomogr

x pnomogr x pnomogr

nomogr

Example B is drawn from d = 15 mm throug Q = 10 l/min. It crosses the Re-line in the laminar area and the result can be read on the laminar scale. p= 0.038 bar x m The nomographic chart applies to the viscosity 25 cSt 3.5E and the density 900 kg/m.

= the oil viscosity in cSt.

At another density a correction is to be made as follows:

nomogr

x pnomogr

= the oil density in kg/m3.

488

Attachments Attachment 1b. Pressure Drop in Bends, Couplings etc.

The nomographic chart apllies to turbulent ow and a density of the oil of 900 kg/m.

p[bar]

1.3 1.2 1.1 1.0 0.9 0.8 0.7 30 0.6 20 0.5 15 100 0.02 90 70 60 50 400 40 200 Q[l(min.] 0.1 0.08 0.06 0.04 3 2 d [mm] 1 0.8 0.6 0.4 0.2 v[m/s] 10 9 8 7 6 5 4

40 20 10

0.01 0.008 1

0.004

0.4 R= 2.5xd 0.35 10 9 8 7 0.3 6 5 0.25 4 4 2 1

0.2

0.15 R= 4xd

p = x

x v2 x 10-5

[bar]

489

GENERAL InfORMATION

For T-connection with a coefcient of resistance = 1.3 the pressure drop is p = 0.17 bar.

MachInes

Q = 100 l/min. and inside diameter of the pipe d = 20 mm. This gives v = 5.4 m/s.

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GS-HYDRO PRODUCT CATALOGUE

GENERAL INFORMATION

Attachments Attachment 2. Oil Flow Rates at Recommended Max. Velocities

Oil ow rate (l/min.) O.D. x ds 6 x 1.0 6 x 1.5 8 x 1.0 8 x 1.5 8 x 2.0 8 x 2.5 10 x 1.0 10 x 1.5 10 x 2.0 10 x 2.5 12 x 1.5 12 x 2.0 12 x 2.5 14 x 1.5 14 x 2.0 15 x 1.5 15 x 2.0 16 x 1.5 16 x 2.0 16 x 2.5 16 x 3.0 18 x 1.5 18 x 2.0 20 x 2.0 20 x 2.5 20 x 3.0 20 x 4.0 22 x 1.5 22 x 2.0 22 x 2.5 25 x 2.0 25 x 2.5 25 x 3.0 25 x 4.0 Suction line v= 1.3 m/s 1 1 2 2 1 1 4 3 2 2 5 4 3 7 6 9 7 10 9 7 6 14 12 16 14 12 9 22 20 18 27 25 22 18 Pressure line v= 5 m/s 4 2 9 6 3 2 15 12 9 6 19 15 12 29 24 34 29 40 34 29 24 53 46 60 53 46 34 85 76 68 104 94 85 68 Return line v= 3 m/s 2 1 5 4 2 1 9 7 5 4 11 9 7 17 14 20 17 24 20 17 14 32 28 36 32 28 20 51 46 41 63 57 51 41 O.D. x ds 28 x 2.0 28 x 2.5 28 x 3.0 30 x 2.0 30 x 3.0 30 x 4.0 35 x 2.0 35 x 3.0 38 x 2.5 38 x 3.0 38 x 4.0 38 x 5.0 42 x 2.0 42 x 3.0 42 x 4.0 50 x 3.0 50 x 5.0 56 x 8.5 60 x 3.0 60 x 5.0 65 x 8.5 66 x 8.5 73 x 3.0 73 x 5.0 73 x 7.0 80 x 10 90 x 3.5 90 x 5.0 97 x 12 115 x 4.0 115 x 15 130 x 15 140 x 4.5 150 x 15 165 x 5.0 220 x 6.0 273 x 6.0 Suction line v= 1.3 m/s 35 32 30 41 35 30 59 52 67 63 55 48 88 79 71 119 98 93 179 153 141 147 275 243 213 220 422 392 326 701 442 612 1051 882 1471 2649 4173 Oil ow rate (l/min.) Pressure line v= 5 m/s 136 125 114 159 136 114 226 198 257 241 212 185 340 305 272 456 377 358 687 589 543 565 1058 935 820 848 1622 1507 1255 2696 17016 2355 4041 3391 5658 10189 16051 Return line v= 3 m/s 81 75 68 96 81 68 136 119 154 145 127 111 204 183 163 274 226 215 412 353 326 339 635 561 492 509 973 904 753 1618 1021 1413 2425 2035 3395 6113 9630

490

Attachments Attachment 3. Recommended Connection Technology

50 bar Section Table Carbon Steel Pipes
Pipe 4X1ST37.4NBK 6X1ST37.4NBK 8X1ST37.4NBK 10X1ST37.4NBK 12X1.5ST37.4NBK 15X1.5ST37.4NBK 16X1.5ST37.4NBK 18X1.5ST37.4NBK 20X2ST37.4NBK 22X1.5ST37.4NBK 25X2ST37.4NBK 28X2ST37.4NBK 30X3ST37.4NBK 35X2ST37.4NBK 38X3ST37.4NBK 42X3ST37.4NBK 50X3ST37.4NBK 60X3ST37.4NBK 73X3ST37.4NBK 90X3.5ST37.4NBK 100X4ST37.4NBK 115X4ST37.4NBK 140X4.5ST37.4NBK 165XST37.4NBK 220X6ST37.4NBK 273X6ST37.4NBK Volume Flow* [l/min] 1 6 5 9 11 20 24 32 36 51 62 81 81 136 145 183 274 412 635 973 1197 1618 2425 3395 6113 9630 Weight [kg/m] 0.05 0.07 0.17 0.22 0.39 0.50 0.54 0.61 0.89 0.76 1.13 1.28 2.00 1.63 2.59 2.89 3.48 4.22 5.18 7.47 9.47 11.0 15.0 18.7 31.9 39.4 37 Flare ange 37 Flare ange 37 Flare ange 37 Flare ange 37 Flare ange 37 Flare ange 37 Flare ange 37 Flare ange 37 Flare ange 37 Flare ange 37 Flare ange 37 Flare ange 37 Flare ange 37 Flare ange 37 Flare ange 37 Flare ange 1/2 3/4 3/4 1 1 1 1/4 1 1/2 2 2 1/2 3 3 1/2 4 5 6 8 10 308F 312F 312F 316F 316F 320F 124F 132F 140F 156F 164F 180F 196F 228F 260F 148F DIN/JIC ttings Connection Type Flange Size Flange Type

50 bar Section Table Stainless Steel Pipes

Pipe 6X1AISI316L 8X1AISI316L 10X1AISI316L 12X1.5AISI316L 15X1.5AISI316L 16X2AISI316L 18X2AISI316L 20X2AISI316L 22X2AISI316L 25X2.5AISI316L 28X2AISI316L 30X3AISI316L 35X2.5AISI316L 38X3AISI316L 42X3AISI316L 50X3AISI316L 60X3AISI316L Volume Flow* [l/min] 2 5 9 11 20 20 28 36 46 57 81 81 127 145 183 274 412 *) v = 3 m/s Weight [kg/m] 0.07 0.17 0.22 0.50 0.69 0.79 0.89 0.99 1.39 1.28 2.00 2.00 2.59 2.89 3.48 4.22 37 Flare ange 37 Flare ange 37 Flare ange 37 Flare ange 37 Flare ange 37 Flare ange 37 Flare ange 37 Flare ange 1/2 3/4 3/4 1 1 1 1/4 1 1/2 2 308F 312F 312F 316F 320F 324F 332F OTHER COMPONENTS 316F ADaPtORs DIN/JIC ttings SWIVELS 0.39 Connection Type Flange Size Flange Type QUICK DISCONNECT

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GENERAL INFORMATION

Attachments Attachment 3. Recommended Connection Technology

210 bar Section Table Carbon Steel Pipes
Pipe 6X1ST37.4NBK 8X1ST37.4NBK 10X1ST37.4NBK 12X1.5ST52.4NBK 16X2ST52.4NBK 20X2.5ST52.4NBK 25X2.5ST52.4NBK 30X3ST52.4NBK 38X3ST52.4NBK 42X4ST52.4NBK 50X5ST52.4NBK 60X5ST52.4NBK 73X5ST52.4NBK 80X10ST52.4NBK 97X12ST52.4NBK 115X15ST52.4NBK 130X15ST52.4NBK 150X15ST52.4NBK 190X20ST52.4NBK 250X25ST52.4NBK Volume Flow* [l/min] 4 8 15 19 34 53 94 136 241 272 377 589 935 848 1256 1702 2356 3393 5301 9425 Weight [kg/m] 0.07 0.17 0.22 0.39 0.69 1.08 1.39 2.00 2.59 3.75 5.55 6.18 8.38 17.2 25.2 37.0 42.5 49.9 83.8 138.7 37 Flare ange 37 Flare ange 37 Flare ange 37 Flare ange 37 Flare ange 37 Flare ange 37 Flare ange Retain ring ange Retain ring ange Retain ring ange Retain ring ange Retain ring ange Retain ring ange Retain ring ange 1/2 3/4 1 1 1/4 1 1/2 2 2 1/2 2 1/2 3 4 4 1/2 5 6 10 308F 312F 316F 320F 324F 332F 340F 340 348 456 860 864 880 896 DIN/JIC ttings Connection Type Flange Size Flange Type

210 bar Section Table Stainless Steel Pipes

Pipe 6X1AISI316L 8X1AISI316L 10X1.5AISI316L 12X1.5AISI316L 16X2AISI316L 18X2AISI316L 20X2.5AISI316L 22X2AISI316L 25X2.5AISI316L 30X3AISI316L 38X4AISI316L 42X4AISI316L 50X5AISI316L 60X5AISI316L 80X10AISI316L 97X12AISI316L 114.3X13.49AISI316L Volume Flow* [l/min] 4 8 12 19 34 46 53 76 94 136 212 272 377 589 848 1256 1702 *) v = 5 m/s Weight [kg/m] 0.07 0.17 0.31 0.39 0.69 0.79 1.08 0.99 1.39 2.00 3.38 3.75 5.55 6.78 17.5 25.5 37.5 37 Flare ange 37 Flare ange 37 Flare ange 37 Flare ange 37 Flare ange 37 Flare ange Retain ring ange Retain ring ange Retain ring ange 1/2 3/4 1 1 1/4 1 1/2 2 2 1/2 3 4 308F 312F 316F 320F 324F 332F 340 348 456 DIN/JIC ttings Connection Type Flange Size Flange Type

492

Attachments Attachment 3. Recommended Connection Technology

280 bar Section Table Carbon Steel Pipes
Pipe 6X1.5ST37.4NBK 8X1.5ST37.4NBK 10X2ST37.4NBK 12X1.5ST52.4NBK 16X2ST52.4NBK 20X2.5ST52.4NBK 25X2.5ST52.4NBK 30X3ST52.4NBK 38X4ST52.4NBK 42X4ST52.4NBK 50X5ST52.4NBK 60X6ST52.4NBK 73X7ST52.4NBK 80X10ST52.4NBK 97X12ST52.4NBK 115X15ST52.4NBK 130X15ST52.4NBK 150X15ST52.4NBK 190X20ST52.4NBK 250X25ST52.4NBK Volume Flow* [l/min] 2 6 8 19 34 53 94 136 212 272 377 543 820 848 1256 1702 2356 3393 5301 9425 Weight [kg/m] 0.17 0.24 0.40 0.39 0.69 1.39 2.00 3.35 3.75 5.55 8.04 11.39 17.2 25.2 37.0 42.5 49.9 83.8 138.7 37 Flare ange 37 Flare ange 37 Flare ange 37 Flare ange 37 Flare ange 37 Flare ange 37 Flare ange Retain ring ange Retain ring ange Retain ring ange Retain ring ange Retain ring ange Retain ring ange Retain ring ange 1/2 3/4 1 1 1/4 1 1/2 2 2 1/2 2 1/2 3 4 4 1/2 5 6 10 308F 312F 316F 320F 324F 332F 440F 440 448 456 860 864 880 896 1.08 DIN/JIC ttings Connection Type Flange Size Flange Type

280 bar Section Table Stainless Steel Pipes

Pipe 6X1AISI316L 8X1.5AISI316L 10X1.5AISI316L 12X1.5AISI316L 16X2AISI316L 20X2.5AISI316L 25X3AISI316L 30X4AISI316L 38X4AISI316L 56X8.5AISI316L 66X8.5AISI316L 80X10AISI316L 97X12AISI316L 114.3X13.49AISI316L NOTE! From 97 and up to 12 use ASTM A312 pipe. Volume Flow* [l/min] 4 6 12 19 34 53 85 114 212 358 566 848 1256 1702 *) v = 5 m/s Weight [kg/m] 0.07 0.24 0.31 0.39 0.69 1.63 3.35 3.38 9.96 12.2 17.5 25.5 37.5 37 Flare ange 37 Flare ange 37 Flare ange Retain ring ange Retain ring ange Retain ring ange Retain ring ange Retain ring ange 1/2 3/4 1 1 1/2 2 2 1/2 3 4 308F 312F 316F 324 332 440 448 456 1.08 DIN/JIC ttings Connection Type Flange Size Flange Type

493

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GENERAL INFORMATION

Attachments Attachment 3. Recommended Connection Technology

350 bar Section Table Carbon Steel Pipes
Pipe 6X1.5ST37.4NBK 8X1.5ST37.4NBK 10X2ST37.4NBK 12X2.5ST52.4NBK 16X2.5ST52.4NBK 20X3ST52.4NBK 25X3ST52.4NBK 30X4ST52.4NBK 39X7.5ST52.4NBK 46X8ST52.4NBK 56X8.5ST52.4NBK 66X8.5ST52.4NBK 80X10ST52.4NBK 97X12ST52.4NBK 115X15ST52.4NBK 130X15ST52.4NBK 150X15ST52.4NBK 190X20ST52.4NBK 250X25ST52.4NBK Volume Flow* [l/min] 2 6 8 12 29 46 85 114 136 198 358 566 848 1256 1702 2356 3393 5301 9425 Weight [kg/m] 0.17 0.24 0.40 0.59 0.83 1.25 1.63 2.51 5.86 7.84 9.96 12.1 17.2 25.2 37.0 42.5 49.9 83.8 138.7 37 Flare ange 37 Flare ange Retain ring ange Retain ring ange Retain ring ange Retain ring ange Retain ring ange Retain ring ange Retain ring ange Retain ring ange Retain ring ange Retain ring ange Retain ring ange 3/4 3/4 1 1 1/4 1 1/2 2 2 1/2 3 4 4 1/2 5 6 10 612F 612F 616 620 624 632 440 448 456 860 864 880 896 DIN/JIC ttings Connection Type Flange Size Flange Type

350 bar Section Table Stainless Steel Pipes

Pipe 6X1AISI316L 8X1.5AISI316L 10X1.5AISI316L 12X2AISI316L 16X2.5AISI316L 20X3AISI316L 25X4AISI316L 30X4AISI316L 38X5AISI316L 56X8.5AISI316L 66X8.5AISI316L 80X10AISI316L 97X12AISI316L NOTE! From 97 and up to 12 use ASTM A312 pipe. Volume Flow* [l/min] 4 6 12 15 29 46 68 114 185 358 566 848 1256 *) v = 5 m/s Weight [kg/m] 0.07 0.24 0.31 0.49 0.83 1.21 2.07 3.35 4.07 9.96 12.2 17.5 25.5 37 Flare ange 37 Flare ange 37 Flare ange 37 Flare ange 37 Flare ange Retain ring ange Retain ring ange Retain ring ange Retain ring ange 1/2 1/2 1/2 3/4 1 1 1/2 2 2 1/2 3 608F 608F 608F 612F 616F 624 632 440 448 DIN/JIC ttings Connection Type Flange Size Flange Type

494

Attachments Attachment 3. Recommended Connection Technology

420 bar Section Table Carbon Steel Pipes
Pipe 6X1.5ST37.4NBK 8X2ST37.4NBK 10X2ST37.4NBK 12X2.5ST52.4NBK 16X2.5ST52.4NBK 20X3ST52.4NBK 25X3ST52.4NBK 30X4ST52.4NBK 39X7.5ST52.4NBK 46X8ST52.4NBK 56X8.5ST52.4NBK 66X8.5ST52.4NBK 80X10ST52.4NBK 97X12ST52.4NBK 115X15ST52.4NBK Volume Flow* [l/min] 2 4 8 12 29 46 85 114 136 198 358 566 848 1256 1702 Weight [kg/m] 0.17 0.30 0.40 0.59 0.83 1.63 2.51 5.86 7.84 9.96 12.1 17.2 25.2 37.0 37 Flare ange 37 Flare ange Retain ring ange Retain ring ange Retain ring ange Retain ring ange Retain ring ange Retain ring ange Retain ring ange 3/4 3/4 1 1 1/4 1 1/2 2 2 1/2 3 4 612F 612F 616 620 624 632 440 448 456 1.25 DIN/JIC ttings Connection Type Flange Size Flange Type

420 bar Section Table Stainless Steel Pipes

Pipe 8X1.5AISI316L 10X2AISI316L 12X2AISI316L 16X2.5AISI316L 20X3AISI316L 25X4AISI316L 38X5AISI316L 56X8.5AISI316L Volume Flow* [l/min] 6 8 15 29 46 68 185 358 Weight [kg/m] 0.24 0.40 0.49 0.83 1.21 2.07 4.07 9.96 37 Flare ange 37 Flare ange Retain ring ange 1/2 1 1 1/2 608F 616F 624 DIN/JIC ttings Connection Type Flange Size Flange Type

690 bar Section Table - Duplex Steel Pipes SAF2205 UNS S31803
Pipe 48.3X10.15SAF2205 60.3X11.07SAF2205 73X14.02SAF2205 88.9X15.24SAF2205 Volume Flow* [l/min] 185 340 472 797 *) v = 5 m/s Weight [kg/m] 9.55 13.44 20.50 27.68 Connection Type Retain ring ange Retain ring ange Retain ring ange Retain ring ange Flange Size 1 1/2 2 2 1/2 3 Flange Type 924/48.3 940/73 948/88.9 932/60.3

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GENERAL InfORMATION

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OTHER COMPONENTS

ADaPtORs

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GENERAL INFORMATION

Attachments Attachment 4a. Hose Size Selection Nomogram

To determine the recommended hose assembly size where the ow rate is known, lay a straight edge across the three colums so that the edge registers with the ow rate gure in the left hand scale, and the recommended velocity range in the right hand scale. The point at which the straight edge intersects the centre scale indicates the recommended hose bore size. Should this reading not coincide with a standard hose assembly bore size, the right hand edge of the straight edge may be adjusted up or down, within the recommended velocity range, until the straight edge registers with a standard bore size in the centre scale. Example: Where ow rate is 100 litres per minute and recommended ow velocity is 4.5 metres per second a 25 mm (1 inch) bore size hose assembly is indicated.

Hose Bore Centimeters

Hose Bore Inches

Metres/sec.

Imp. gallons per minute

Flow Litres per minute

Note: Flow velocities in range A are recommended for suction and return lines. Flow velocities in range B are recommended for delivery lines.

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Flow velocity

Feet/sec.

Attachments Attachment 4b. Pressure Drop in Hoses

The pressure drop in hoses is determined based on the following information: type of application, uid type and viscosity (at desired temperature), uid temperature, uid ow rate, hose size and length, number and type of ttings. The following graph will help you to determine the amount of pressure drop.

Imperial gallons per minute BIte tyPe fIttIngs Pressure loss in millibars per metre Pressure loss in PSI per metre Litres per minute Based on: uid viscosity 20 cSt specic gravity 0.875

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Attachments Attachment 4c. Bending Radius Theory for Hoses

When a hose is bent between two points, it should not bend more than its minimum bend radius, under given maximum working pressure. When hose is used beyond specied recommendations, unnecessary strain on the reinforcement and/or hose / coupling interface will shorten assembly life. Minimum bend radius for steel reinforced hose is determined under impulse testing and is specied on GS data sheet for each hose type.

To identify the hose length necessary to respect the minimum

dOD L=(R+ 2

) x 2 x 360 +2S

where L = hose length R = bend radius, in mm dOD = outside diameter, in mm = bend angle S = straight hose portion on coupling

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Attachments Attachment 5. Spacing for Clamps

Max. distances between clamps for GS-pipes Pipe size [mm] 20 X 2 25 X 2.5 30 X 3 38 X 4 42 X 4 50 X 3 50 X 5 56 X 8.5 60 X 3 60 X 5 66 X 8.5 75 X 3 80 X 10 90 X 3.5 90 X 5 97 X 12 100 X 4 115 X 4 115 X 15 130 X 15 140 X 4.5 150 X 15 165 X 5 190 X 20 220 X 6 250 X 25 273 X 6 Marine hydraulics* [m] 1.1 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.9 2.0 2.0 2.1 2.2 2.3 2.4 2.5 2.4 2.6 2.7 2.9 2.8 3.1 3.0 3.5 3.5 4.0 3.5 * = Vibration calculations are based on ships with max. propeller speed 2 rev/sec and max. number of propeller blades 6 (frequence 12 Hz) Industrial hydraulics [m] 1.5 2.1 2.1 2.3 2.7 2.8 3.0 3.2 3.5 3.6 3.7 3.7 4.0 4.0 4.3 4.3 4.9 5.0 5.2 5.4 5.8 6.0 5.4 4.6 3.0 2.7 1.2

Note! Detailed engineering performed by GS-Hydro is recommended in order to ensure proper clamp locations and spacing. GS-Hydros engineering services can also include a FEM-analysis of the stresses in the piping system (the FEM analysis is performed upon separate order).

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Attachments Attachment 6. Linear Expansion of Steel Pipes

Pipe lenght, m 100 80 63 50 40 31.5 25 20 16 12.5 10 8 6.3 5 4 3.15 2.5 2 1.6 1.25 1 Variation in lenght, mm 160 100 63 40 27.5 16 10 6.3 4 2.5 1.6 1 0.63 0.4 0.25 0.16 0.1 Temperature difference, C 125 100 80 63 50 40 31.5 25 20 16 12.5 10 8

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Attachments Attachment 7. Thread identication

Thread Identication O.D. [mm] 7.95 8.00 9.73 10.00 10.27 11.11 12.00 12.70 13.16 13.57 14.00 14.27 15.88 16.00 16.66 17.06 18.00 19.05 20.00 20.96 21.22 22.00 22.23 22.91 24.00 26.00 26.44 26.57 26.99 27.00 28.00 30.00 30.16 30.20 31.23 33.25 33.34 36.00 41.28 41.91 41.99 42.00 45.00 47.63 47.80 48.05 52.00 59.60 60.09 63.50 65.71 73.00 75.18 87.88 89.00 113.03 114.35 I.D. [mm] 6.78 6.92 8.57 8.92 8.77 9.74 10.38 11.33 11.45 11.31 12.38 12.76 14.35 14.38 14.95 14.80 16.38 17.33 18.38 18.63 18.32 20.38 20.26 20.59 22.38 24.38 24.12 23.67 25.10 24.83 26.38 27.83 28.20 27.88 29.61 30.29 31.40 33.83 39.30 38.95 38.95 39.83 42.83 45.80 44.85 44.52 49.83 56.66 56.56 60.80 62.75 68.80 72.23 84.93 85.00 110.70 110.38 Type of thread 5/16UNF 1/8BSP M10 1/8NPT 7/16UNF M12 1/2UNF 1/4BSP 1/4NPT 9/16UNF 5/8UNF M16 3/8BSP M18 3/4UNF M20 1/2BSP 1/2NPT M22 7/8UNF 5/8BSP M24 M26 3/4BSP 3/4NPT 1 1/16UN M27 M28 M30 1 3/16UN 7/8BSP 1BSP 1 5/16UN M36 1 5/8UN 1 1/4BSP 1 1/4NPT M42 M45 1 7/8UN 1 1/2BSP 1 1/2NPT M52 2BSP 2 1/2UN 2 1/4BSP 2 1/2NPT 2 1/2BSP 3BSP 3NPT 4BSP 4NPT 2NPT 42L, 38S 2.0 -24 12 30S 35L 2.0 2.0 -20 12 -16 12 28L, 25S 2.0 1NPT 22L, 20S -12 12 2.0 2.0 2.0 16S 18L 1.5 1.5 -10 14 15L, 14S 1.5 -08 16 12S 1.5 12L, 10S 1.5 3/8NPT 10L, 08S 1.5 -06 18 M14 08L, 06S 1.5 -05 20 -04 20 08LL, 06L 1.0, 1.5 06LL 1.0 M8 Size JIC Pitch Size 04LL DIN Pitch 1.0

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Cleanliness Introduction Cleanliness

The cleanliness of hydraulic piping systems is of utmost importance. Research shows that in average 80% of the operational problems of hydraulic systems are related to impurities in the system. An important cause of the impurties are the welds in a welded piping system (or when utilising welded anges). The oil purity is typically presented in accordance with the following standards: ISO 4406 or NAS 1638.

ISO 4406:1987 and ISO 4406:1999

Standards ISO 4406:1987 and ISO 4406:1999 dene the oil purity class based on the cumulative particle count in three different particle size ranges (2 / 5 / 15 m and 4 / 6 / 14 m respectively). The purity class is dened for each size range based the number of particles which are of the specied size or larger. ISO 4406:1999 denes the oil purity on scale from 0-28 (:1987 is otherwise the same but class 0 is missing) ISO 4406:1999-oil purity classes and particle count (no. of particles per 100 ml) for particle size ranges 4 / 6 / 14 m
Particle count / 100 ml > 130 000 000 64 000 000 32 000 000 16 000 000 8 000 000 4 000 000 2 000 000 1 000 000 500 000 250 000 130 000 64 000 32 000 16 000 8 000 4 000 2 000 1 000 500 250 130 64 32 16 8 4 2 1 0 250 000 000 130 000 000 64 000 000 32 000 000 16 000 000 8 000 000 4 000 000 2 000 000 1 000 000 500 000 250 000 130 000 64 000 32 000 16 000 8 000 4 000 2 000 1 000 500 250 130 64 32 16 8 4 2 1 ISO-class 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

example ISO 4406:1999 15/13/10 is equal to : the no. of particles 4 m corresponds to class 15 ie. 16,00132,000 / 100 ml the no. of particles 6 m corresponds to class 13 ie. 16,00132,000 / 100 ml the no. of particles 14 m corresponds to class 10 ie. 16,00132,000 / 100 ml

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Cleanliness NAS 1638

The NAS 1638 standard utilises five (5) particle size ranges and thirteen (13) oil purity classes between 0012. The oil purity (particle count) is measured and the oil purity class defined independently for all five size ranges. The NAS 1638 oil purity class is then given with a single figure which is the lowest (impurest) of the measured five size ranges. A more precise view of the purity is obtained if the NASclass is provided separately for all ve size ranges. NAS 1638-oil purity classes (no. of particles per 100 ml)
Particle count / 100 ml 515 m 125 250 500 1 000 2 000 4 000 8 000 16 000 32 000 64 000 128 000 256 000 512 000 1 024 000 1525 m 22 44 89 178 256 712 1 425 2 850 5 700 11 400 22 800 45 600 91 200 182 400 2550 m 4 8 16 32 63 126 253 506 1 012 2 025 4 050 8 100 16 200 32 400 50100 m 1 2 3 6 11 22 45 90 128 360 720 1 440 2 880 5 760 > 100 m 0 0 1 1 2 4 8 16 32 64 128 256 512 1 024

00 0

2 3 4 5 6 7 8 9 10 11 12

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example NAS 7 is equal to (for instance): the no. of particles 515 m is 25,000/100 ml the no. of particles 1525 m is 1,400/100 ml the no. of particles 2550 m is 63/100 ml the no. of particles 50100 m is 45/100 ml the no. of particles > 100 m is 4/100 ml

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Cleanliness SAE AS4059

The SAE AS4059-standard is based on the NAS 1638-standard. The SAE AS4059-standard utilises particle sizes defined in the ISO 11171-standard. The oil purity class is based on the cumulative particle count (in a similar fashion as in the ISO-4406 standard). SAE AS4059 oil purity classes (no. of particles per 100 ml)
Particle count / 100 ml > 4 m A 195 390 780 1 560 3 120 6 250 12 500 25 000 50 000 100 000 200 000 400 000 800 000 1 600 000 3 200 000 > 6 m B 76 152 304 609 1 220 2 430 4 860 9 730 19 500 38 900 77 900 156 000 311 000 623 000 1 250 000 > 14 m C 14 27 54 109 217 432 864 1 730 3 460 6 920 13 900 27 700 55 400 111 000 222 000 > 21 m D 3 5 10 20 39 76 152 306 612 1 220 2 450 4 900 9 800 19 600 39 200 > 38 m E 1 1 2 4 7 13 26 53 106 212 424 848 1 700 3 390 6 780 > 70 m F 0 0 0 1 1 2 4 8 16 32 64 128 256 512 1 020 AS4059-class 000 00 0 1 2 3 4 5 6 7 8 9 10 11 12

example According to the SAE AS4506-standard the oil purity can be dened: with a single class; for instance 6 or 6B with a independent class for each size; for instance 6B/5C/4D/3E with the maximum oil purity class of a larger range; for instance 6 B-F

The oil purity is dependent on the application and equipment. All manufacturers have their own recommendations for their own, specic equipment and machinery. The following table provides the general guidelines for various types of hydraulic systems as well as a comparison between the various standards.
ISO 4406: 1987 (ACFTD) 2 / 5 / 15 m Servosystems Proportional systems Other systems (17)/13/10 (18)/15/12 (19)/16/13 ISO 4406: 1999 4 / 6 / 14 (c) m 18/13/10 20/15/12 22/16/13 NAS 1638 NAS 4 NAS 6 NAS 7

According to the ISO 4402-standard the size of an ACFT-particle is dened in accordance with the maximum dimension of the particle. In the newer ISO 11171-standard the ISO MTD particle size is dened as the diameter of a circle with the same area (as the actual particle). The designation c (certied) is utilised to identify the particle size.

Particle

A= 176.7 m

Standard

ACFTD ISO 4402 (1991)

ISO MTD ISO 11171 (1999)

A= 176.7 m
Denition of particle size

A= 176.7 m

d= 16.9 m
Particle size 16.9 m

d= 15 m
15 m (c)

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